Yarn Processing/Making/Manufacturing process roughly includes:
1:Preparing the fibers 2:Carding 3:Combing 4:Drawing out 5:Twisting 6:Spinning
Urning synthetic fibers into yarn is not an easy process. It comprises a series of processes that decide the yarn characteristics like size, quality, texture, etc. Let’s walk you through the different steps of processing the fine quality yarns.

What is fancy yarn?
Fancy yarns refer to single-ply yarns with structural and morphological changes. Its spinning method is to adopt special processes or devices in the processes of carding, roving and spinning, so as to change the structure and shape of the yarn, so that the surface of the yarn has “dot” and “node” patterns. For example, the surface of the knot yarn is granular with dots attached to the surface of the yarn; the surface of the slub yarn is intermittent thick details; the surface of the interrupted AB yarn is a section of single-color yarn, and the other section is alternately distributed with two-color AB yarn. The length of this thick detail or single color and AB yarn can be determined according to the requirements of the subsequent products, which can be long or short, thick or thin, and the spacing can be thin or dense, and can be adjusted regularly or irregularly.

01. Spandex core spun yarn
The spandex core-spun yarn is fed into a stretched spandex filament (usually stretched 3~4 times) between the middle roller and the front roller of the ordinary spinning frame and merged with the drafted whiskers, and the front roller makes the yarn. The original ribbon-shaped fiber must be wrapped around the outside of the spandex yarn. The linear density of this type of yarn is generally 12-30tex (33-83 male counts), which can be used for knitted fabrics or woven fabrics. The fabrics are elastic and comfortable to wear. At present, most of the spandex core-spun yarns are cotton covered with ammonia, but also polyester covered with ammonia. The spandex core-spun yarn can also be produced on a double-roller twisting machine or a special covering machine, and the outer surface of the spandex yarn is covered with a layer of cotton yarn or nylon filament; some are covered with silk for the collar of a silk T-shirt. The shrinkage of spandex yarn can make the knitted collar stiff.

02. Polyester core spun yarn
Polyester core-spun yarn is formed by feeding a high-strength polyester filament between the center roller and the front roller on an ordinary spinning frame, and wrapping the original ribbon-like fibers on the surface of the polyester filament through the front roller. The yarn can be made into high-strength polyester sewing thread by plying again, which not only has high strength, but also is not easy to heat up when passing through the needle eye of a high-speed sewing machine after the surface is covered with a layer of cotton fiber. This kind of yarn can also be woven into canvas as a conveyor belt, which not only has high strength, but also has good adhesion performance with rubber after the surface is covered with cotton fiber, which overcomes the disadvantage of poor affinity between polyester and rubber. Polyester-cotton core-spun yarn can be used as polyester-cotton burnt-out cloth.

03. Metal Core Yarn
The metal core-spun yarn is a metal monofilament with a diameter of 25um wrapped with cotton fibers. The spinning method is similar to that of the polyester core-spun yarn. In the process, it should be noted that the unwinding of the metal wire package should be radially positive unwinding. When weaving with this core-spun yarn, it is generally used as a weft yarn, which is arranged in a 1:1 or 1:2 arrangement with ordinary yarns. This kind of fabric can be used for the cover of national defense radar, and can also be used for civilian radiation protection work clothes or aprons, etc., and has a wide range of uses.

HKV151B (BI) Fancy Yarn Twisting Machine is a new type of special yarn spinning machine with wide adaptability and complete functions.  Its fancy shape is completed by microcomputer and frequency conversion control technology, which is suitable for spinning various types of fancy yarns, such as loop yarn, slub yarn, corrugated yarn, multi-color knot yarn, etc.

Product Features

1. Swing-open spindle, easy to operate and large feeding capacity.
2. The speed of each roller, spindle, false twister and coiler is individually controlled by frequency conversion and PLC program control, which is easy to operate and accurate in process.
3. The unique comb device has independent patent property rights, and the output of bamboo products is obviously more than doubled, and the production efficiency is doubled.
4. Three-layer creel is suitable for feeding more raw materials.

User-selectable components

Four-layer creel: suitable for feeding more raw materials.

Application: Suitable for elastic and non-elastic covered core, such as spandex, nylon, polyeste。

Texturing Machine Stretch Ratio:
The draw ratio is generally determined by the residual draw ratio of POY, which directly affects the fineness, strength and elongation of the silk. With the increase of draw ratio, the strength of the filament increases, the elongation decreases, the crimp rate is low, and the crimp stability increases. This is mainly because with the increase of the draw ratio, the macromolecules of the fibers are stretched and aligned along the fiber axis, the orientation degree of the drawn filaments increases, and the crystallization of macromolecules is induced at the same time, thereby increasing the strength of the filaments. Due to the increase in the degree of orientation of macromolecules in the fiber at high draw ratios, the possibility of further stretching decreases, so during the drawing process, the ability to be re-stretched decreases; in addition, due to the increase in the draw ratio, the tension High limits the rapid displacement required for the development of fiber crimps, and the fibers are densely crimped, so the crimp rate decreases and the crimp stability increases. If the stretching ratio is too low, the tension is small, and it is easy to fluctuate and slip, resulting in tight twist. Therefore, appropriately increasing the draw ratio within a certain range can stabilize the twisting, the difference between the spindles is small, the A rate of dyeing is increased, and the difference in post-processing can be reduced. For single slender fibers, the stretch should not be too large, and the adjustable range is relatively narrow.

HKV151B (BI) Fancy Yarn Twisting Machine is a new type of special yarn spinning machine with wide adaptability and complete functions. Its fancy shape is completed by microcomputer and frequency conversion control technology, which is suitable for spinning various types of fancy yarns, such as loop yarn, slub yarn, corrugated yarn, multi-color knot yarn, etc.

Product Features
1. Swing-open spindle, easy to operate and large feeding capacity.
2. The speed of each roller, spindle, false twister and coiler is individually controlled by frequency conversion and PLC program control, which is easy to operate and accurate in process.
3. The unique comb device has independent patent property rights, and the output of bamboo products is obviously more than doubled, and the production efficiency is doubled.
4. Three-layer creel is suitable for feeding more raw materials.

User-selectable components
Four-layer creel: suitable for feeding more raw materials.

HKV151B (BI) Fancy Yarn Twisting Machine is a new type of special yarn spinning machine with wide adaptability and complete functions.  Its fancy shape is completed by microcomputer and frequency conversion control technology, which is suitable for spinning various types of fancy yarns, such as loop yarn, slub yarn, corrugated yarn, multi-color knot yarn, etc.

HKV151B (BI) Fancy Yarn Twisting Machine is a new type of special yarn spinning machine with wide adaptability and complete functions.  Its fancy shape is completed by microcomputer and frequency conversion control technology, which is suitable for spinning various types of fancy yarns, such as loop yarn, slub yarn, corrugated yarn, multi-color knot yarn, etc.

Product Features

1. Swing-open spindle, easy to operate and large feeding capacity.
2. The speed of each roller, spindle, false twister and coiler is individually controlled by frequency conversion and PLC program control, which is easy to operate and accurate in process.
3. The unique comb device has independent patent property rights, and the output of bamboo products is obviously more than doubled, and the production efficiency is doubled.
4. Three-layer creel is suitable for feeding more raw materials.

User-selectable components

Four-layer creel: suitable for feeding more raw materials.

Product Features:

1. Swing-open spindle, easy to operate and large feeding capacity.
2. The speed of each roller, spindle, false twister and coiler is individually controlled by frequency conversion and PLC program control, which is easy to operate and accurate in process.
3. The unique comb device has independent patent property rights, and the output of bamboo products is obviously more than doubled, and the production efficiency is doubled.
4. Three-layer creel is suitable for feeding more raw materials.

User-selectable components:

Four-layer creel: suitable for feeding more raw materials.

The air covering machine has the following functions: it feeds continuous fibers such as polyurethane yarn, generally known as spandex, nylon and polyester, into an interlacing nozzle with a feed roller set at arbitrary speed, interlaces that yarn with air using turbulence generated by compressed air inside the nozzle, and then produces yarn known as Air-Coated Yarn ACY.

Air-Coated Yarn (abbreviated as empty bag, abbreviated as ACY in English) is a yarn that is formed by a pair of nozzles and a spandex yarn through a certain type of nozzle, which is formed by a high-compression air jet to form a rhythmic network point. . The fabric feels soft and smooth; the mechanical covering yarn (referred to as the machine package, abbreviated as SCY) is to continuously rotate the outer fiber filament and wrap it on the core silk spandex which is uniformly drawn, which is twisted and twisted. (English abbreviation for TPM), the fabric style is flat and its main features.

The machine starts slowly with inverter, stable performance, easy operation. Individual spindle control, set length stop. When the yarn is full on the bobbin or yarn broken, the spindle will stop automatically.

It’s a highly cost effective machine ( small investment, large capacity, convenient production and different spindle can produce different yarn size). The final product suits for the seamless underwear, socks, gloves and so on.

Machine can be used to make for the FDY intermingle point. (option)

Features: Each Spindle with Air Jet, Individual Oiling System, Yarn Sensor Device and Tensioner.

Air-covered yarn (ACY) is a yarn in which the outer fiber filament and spandex yarn are drawn through a certain type of nozzle at the same time, and the rhythmic network point is formed by the regular spray pressure of high-compressed air.

When you are delving in the production of yarn, you will realize that different materials have different requirements for production. To efficiently produce thread for spandex, polyester, nylon, and lycra; investing in a quality classic Air Jet Covering Machine is imperative.

In the spinning process, the spandex stretch is an important process parameter, which affects the coverage of the covered yarn and the elasticity of the fabric, and affects the elongation of the covered yarn. Uniformity and creep properties. The pre-draw ratio of spandex is too small, and the advantage of elasticity of elastic fabric can not be fully utilized. When the drafting is too high, the spinning is difficult, and the yarn breaks easily, and the product quality decreases. In addition, the percentage of spandex yarn also affects. The covered yarn has high elasticity, high content and good elasticity. In the case of a certain size of the spandex yarn, the draw ratio is increased, and the percentage of the spandex yarn is lowered, that is, the pre-draw ratio of the spandex is inversely proportional to the percentage of the spandex.

The tensile strength of the covered yarn increases with the increase of the pre-draw ratio of the spandex. After the drafting reaches a certain value, the shrinkage of the spandex yarn causes the outer fiber to be curled, and the spandex core wire is straightened; The pre-draw ratio, the percentage of spandex is reduced, and the degree of crimping of the outer fiber is large. However, when the drafting is too large, the deformation amplitude of the spandex yarn is close to the critical value of the deformation, which will cause the strength of the covered yarn to decrease, but it is advantageous for the coated yarn to be evenly dried.

The powerful yarn texturizing machine produce quality yarns for premium fabrics. The low cost of maintenance and operation lowers the cost of production, giving better profits. The mechanical parts are easily replaceable, helping reduce the hassle of finding spare parts. Compact packaging of these machines protects them against damage on-transit.

Modern technology yarn products appeal to many buyers seeking quality fabrics. High-production double spindles yarn texturizing machine have better warranties for after-sales services. The reasonable delivery times allow various textile businesses to begin production in real-time.

Application of an auto-doffing device allows less manpower to be needed and for the yarn to be maintained at the specified length. These features suit application to warp yarn. Special yarn such as differential shrinkage yarn for use in peachskin-like fabrics and slub yarn (knubbed yarn) for splash-pattern fabrics can also be produced depending on the specifications of the machine used.

Nylon ATY is often used in sportswear, umbrellas and bags.

Fabric woven with this yarn has been utilized in famous sports brands and is well-known all over the world.

Finishing process of wool fabric
Due to the wide variety of wool fabrics, the finishing process also has certain differences. For example, glossy fabrics may involve: green body repairing → singeing → washing → cooking → dyeing → water absorption → drying – middle inspection → cooked repair → bristles → Shearing → Wetting and parking → Steaming → Voltage; while the suede fabric involves: preparation → washing → dehydrating → shrinking → washing → dyeing → dehydrating → drying → middle inspection → finishing → fluffing → bristle shearing → steaming Brushing → steaming, so today we will discuss the purpose and principle of the general finishing process.

01 Carbonization
Purpose: to remove vegetable impurities from wool. Principle: Utilize the difference in the resistance of wool and cellulose impurities to acid to remove impurities. The acid promotes the hydrolysis of cellulose impurities, making them brittle, and is removed by rolling and washing; while the -NH2 on the wool absorbs H+, and starts to absorb acid from pH=5, and reaches saturation at pH=1, which does not damage the wool. If acid absorption continues, the main chain of wool will be hydrolyzed, so the acid concentration and temperature should be strictly controlled in the production process.

02 What to wash
Purpose: Purify and improve hand feel. Principle: Generally, surfactants are used to wash the woolen blanks, so as to remove impurities and improve the hand feeling. The wool fabric moves and squeezes continuously during washing, which has a certain shrinking effect. When the fabric is required to feel full, the washing time can reach about 2 hours, and the washing time of general wool fabrics is 45 to 90 minutes. After washing it, wash it off with warm water around 40°C.

03 Boiled and steamed
Purpose: To make the fabric dimensionally stable, smooth, natural luster, soft to the touch and elastic. Principle: Wool fiber is subjected to uneven external force during spinning and weaving, causing internal stress in the fabric. Under humid and hot conditions, due to the relaxation of internal stress, uneven shrinkage is caused. New crosslinks are established in new locations, creating a styling effect.

04 Shrink it
Purpose: After the wool fabric is wetted by a wetting agent under a certain temperature condition, under the repeated action of mechanical external force, the fibers are entangled and entangled with each other, so that the fabric shrinks, the thickness increases, and a layer of fluff is formed on the surface to cover the texture. crafting process. Principle: The friction coefficient of wool moving against the scales (pointing to the hair tip) is larger than the friction number moving along the scales (pointing to the hair root), which is called the directional friction effect. When the shrinkage agent exists, repeated random external forces force the wool to move along the scales, so the roots of the wool bite each other, and the tips of the fibers cover the surface of the fabric in a free state. Due to the disordered arrangement of the fibers, the result of the movement tends to shrink.

05 Anti-felt shrinkage
Purpose: To reduce the downing of wool fabrics, to obtain dimensional stability of the fabrics, and to reduce the phenomenon of pilling. Principle: By reducing the directional friction effect, the inherent elasticity of wool is improved and the mutual movement of wool is restricted. Anti-felting is usually achieved by depositing wool-destroying flake layers and polymers on the surface of the fabric.

Air-jet spinning is also known as Vortex or fasciated yarn spinning. Before the sliver from the drawframe is supplied to the air-jet spinner, combing is often used, as it is imperative to get rid of any dust or trash that could obstruct the spinning jets. Twist is inserted to the fibres, mostly on the yarn surface, by the vortex created in one or two air-jet nozzles. The resulting yarn consists of a core of parallel fibres and a sheath of wrapped (twisted) fibres. The yarn produced by air-jet spinning resembles a ring-spun yarn but is not as strong. The yarns are also inclined to shrink. High delivery rates of 150–450 m/min are possible with this technique.

The feed material, i.e. the slivers, is fed to the four-roller drafting arrangement. The fibres come out of the front rollers, are sucked into the spiral orifice at the entrance of the air-jet nozzle, and are then held together more firmly as they move towards the tip of the needle protruding from the orifice. At this stage, the fibres are twisted by the force of the air-jet stream. This twisting motion tends to flow upwards. The needle, which acts as a guide on the needle holder, projects towards the inlets of a hollow spindle. A nozzle block provides a swirling air current, which acts on the drafted fibre bundle. The needle protruding from the orifice prevents this upward propagation (twist penetration). Therefore, the upper portions of some fibres are separated from the nip point between the front rollers, but are kept ‘open’. After the fibres have passed through the orifice, the upper portions of the fibres begin to expand due to the whirling force of the air-jet stream and twine over the hollow spindle.

The fibre bundle is then sucked into the hollow spindle, and twist insertion starts when the fibre bundle is subjected to a compressed air vortex as it enters the spindle. Twist propagation towards the nip of the front rollers is prevented by the guide members acting as the centre of the fibre bundle. On leaving the guide member, the whirling action of the air current separates the fibres randomly towards the bundle.

The leading ends of all the fibres are held into the body of the yarn being formed, while the trailing ends leaving the front roller nip set are whirled up in the air and are inverted and separated from each other at the inlet of the hollow spindle. The leading ends are less subject to the air current as they are moved around the guide member towards the inlet of the spindle and converted into spun yarn. The fibres twined over the spindle are whirled around the fibre core and made into vortex yarn as they are drawn into the spindle.

The finished yarn is wound onto a package after any defects have been removed. The final package is then removed automatically. The leading ends of the fibre bundle are drawn into the hollow spindle by the fibres of the preceding portion of the bundle being twisted into a spun yarn. The trailing ends of the fibres are inverted at the inlet, separated from each other, and exposed to the swirling air blown through the nozzles. The trailing ends of the fibres are thereby caused to twist around the porting of the fibre bundle being converted into a spun yarn.

Some fibers, particularly those at the edges of the ribbon, will not be subjected to the full twisting action imparted to the main body of fibers by the downstream air-jet. Hence they receive less twist than those fibers in the main bundle. When the yarn gets untwisted in the downstream of the twister, the low twist edge fibers get untwisted to a greater degree than their original twist. Therefore they are given a true twist in the direction opposite to that of the upstream twist.

The main body of the strand will be untwisted into parallel fibers, forming the core and these will be wrapped around by the edge fibers forming the wrapper fiber layer or the sheath, thus forming a fasciated yarn.

The function of the back nozzle is to enhance the cohesion of the strand thus giving greater yarn strength.Since the direction of airflow in the back nozzle is opposite to that of the front nozzle, the back nozzle tends to untwist the wrapper fibers as they are formed inside the front nozzle. This increases the length of wrapping, thus improving the yarn cohesion.

The air-jet spun yarn consists of an untwisted core of parallel fibers and a surface wrapping of fibers. The core fibers account for approximately 85-95% of the yarn mass. The surface wrapper fibers are helical in nature unlike the wrapper fibers in the rotor yarn.

The wrapper fibers are not uniformly distributed over the length; sometimes they are more on the surface and sometimes very few are on the surface. Their frequency and tightness being influenced by the fiber physical properties and the spinning process parameters. “The high level of constriction of the straight core fibers by the surface wrapper fibers results in high bending modulus of air-jet yarns”.

Spinning

Polymer that is to be converted into fibre must first be converted to a liquid or semiliquid state, either by being dissolved in a solvent or by being heated until molten. This process frees the long molecules from close association with one another, allowing them to move independently. The resulting liquid is extruded through small holes in a device known as a spinnerette, emerging as fine jets of liquid that harden to form solid rods with all the superficial characteristics of a very long fibre, or filament. This extrusion of liquid fibre-forming polymer, followed by hardening to form filaments, is called spinning (a term that is actually more properly used in connection with textile manufacturing). Several spinning techniques are used in the production of man-made fibre, including solution spinning (wet or dry), melt spinning, gel spinning (a variant on solution spinning), and emulsion spinning (another variation of solution spinning).

Texturing is the formation of crimp, loops, coils, or crinkles in filaments. Such changes in the physical form of a fibre affect the behaviour and hand of fabrics made from them. Hand, or handle, is a general term for the characteristics perceived by the sense of touch when a fabric is held in the hand, such as drapability, softness, elasticity, coolness or warmth, stiffness, roughness, and resilience.

Air-jet texturising process is a purely mechanical method that uses a cold air-stream to produce bulked yarns of low extensibility. The feed yarns need not be restricted to the synthetic filament yarns. The air-textured yarns resemble spun yarns in their appearance and physical characteristics. The air-jet texturising process is by far the most versatile of all the yarn texturising methods in that it can blend filaments together during processing.